Construction material and process of producing the same



R. P. PERRY.

CONSTRUCTION MATERIAL AND PROCESS OF PRODUCING THE SAME.

APPLICATION FILED OCT. 9. 1917.

1,369,186. Patented Feb. 22, 1921.

4 Ill/4W v 7 III/VENTOR A TTORNEY UNITED STATES PATENT OFFICE.

RAY I. PERRY, OF UPPER MONTCLAIR, NEWJERSEY, ASSIGN OR TO THE BARRETTCOMPANY, A. CORPORATION OF NEW JERSEY.

CONSTRUCTION MATERIAL AND PROCESS OF PRODUCING THE SAME.

Specification of Letters Patent.

Patented Feb. 22, 1921.

Application filed October 9, 1917. Serial No. 195,655.

To all whom it may concern: Be it known that I, RAY P. PERRY, a c1t1-zen of the United States, residing at Upper Montclair, in the county ofEssex and State of New Jersey, have invented certain new and usefulImprovements in Construction Materials and Processes of Producing theSame, of which the followingis a specification.

My invention relates to an improved form of dry or unsaturated felt orpaper adapted to be saturated with a waterproofing material, to thesaturated felt resulting therefrom, and in the saturating process. Thesocalled dry felt or unsaturated paper used in the manufacture of tarredor asphalt saturated felts and rubber roofings is ordinarily made in theform of plain sheets having a substantially uniform thickness througout,the sheets being generally put up in rolls. This dry felt is ordinarilysaturated by passing it through a bath containing the Water proofingmaterial, such as tar or asphalt compositions, in hot liquid form andthen through squeeze rolls to remove the surplus waterproofing materialon the surfaces of the felt. The felt is then ordinarily wound intorolls for sale or use in further processes. The dry felt or paperheretofore made is ordinarily of varying porosity and varying absorbentcapacity for the saturating material. This variation in quality obtainsnot only in different rolls but generally within the same roll, due inpart probably to the uneven quality of pulp used and to the unevenfelting or forming of the sheet, which factors cannot be absolutelycontrolled. The result is that the dry felt of waterproofing material tobe absorbed by my felt or paper.

In working my process I provide a felt or paper provided with aplurality of depressions of substantially predetermined cubical contenteither on one or both sides of such felt or paper. Preferably thedepressions on each side of the felt or paper, where such depressionsare provided on both sides, are

staggered with relation to each other and with relation to thedepressions on the other side, though satisfactory results may beobtamed without staggering such depressions. lfVhlle the depressions maybe made in the felt or paper while the same is still in a very moistcondition, as shortly before it reaches the driers in the method usuallyemployed in the manufacture of felt or paper, or after the sheet hasbeen dried, I prefer to make such depressions after the felt has beenpartly dried and is in a somewhat moist condition, although satisfactoryresults are obtained by any of the modes of procedure on one or botsides of the same, is later led through the saturating device where thedepressions are filled with the waterproofing material. Since thedepressions are of predetermined cubical content, the amount ofwaterproofing material filling such depressions will also bepredetermined, and in this way I am enabled to determine, withconsiderable accuracy, the exact amount of saturating material appliedto the sheet. While several methods of filling the depressions may beused to advantage, I prefer to fill such depressions by passing theprepared sheet or strip .of felt having the depressions on one or bothsides thereof in a vertical position downward between two guiding rollsabove which, on each side of the felt, there is provided a source ofliquid waterproofing material. The waterproofing material covers bothsides of the felt where both sides are depressed (but one side may bewith' such depressions, I effect a more uniform distrlbution of theliquid water roofing material in the final saturate felt. This isespecially true where the depressions have oblique sides, which permitsthe saturation to take place uniformly and with in creased rapidity. Thestaggering of the depressions also leaves the felt as strong'aspossible, since forming the. depressions at opposing points on the twosides of, the felt would have a tendency to weaken the same.

Referring to the drawing, wherein I have I illustrated severalembodiments of my invention,

Figure 1 shows in plan view a portion of a strip of felt provided on oneside of the same with depressions for the purpose set forth;

Fig. 2 is a cross-section of the felt shown in Fig. 1 along the sectionline AA;

Fig. 3is a sectional view of a strip of felt provided with depressionson both sides of the same;

Fig. 4 illustrates diagrammatically the means for applying liquidwaterproofing material to a strip of felt having depressions on one sideof the same;

Fig. 5 illustrates diagrammatically means for applying liquidwaterproofing material to the depressions in a strip of felt, both sidesof said strip being provided with depressions; and

Fig. 6 shows in plan View a further modification.

Referring particularly to Figs. 1,2 and 4 of the drawing, 1 indicates astrip of felt provided with the depressions 3 which are defined by theraised portions 2. Preferably these depressions. are provided withoblique or slanting sides, as illustrated, though other forms'ofdepressions may be used to advantage. Furthermore, I prefer to staggerthe depressions with relation to each other, thereby effecting a moreuniform distribution of the saturating material. However, the inventionmay be practised to advantage where the depressions are in a straightline rather than staggered. Where the depressions are in a straightline, or in other desired arrangement of the same, they may consist oflong channels extending across the sheet almost or entirely to the edgesthereof, as shown in Fig. 6, where the strig of felt 19 has thedepressions 20 de fine by the transverse raised portions 21, and the endraised portions 22. As previously stated, I prefer to provide the sheetwith the depressions after it has been partially dried, that is, afterit has passed over some but not all of the heated drying rolls commonlyemployed in the manufacture of felt or paper. The strip 1, provided withthe depressions as set forth, passes to the saturating device. I preferto use the means illustrated in Fig. 4 for efiecting a saturation of thedry felt by filling the depressions 3 with liquid waterproofingmaterial, though other forms of filling means may be employed toadvantage. Referring to thedevice diagrammatically illustrated in Fig.4, the felt is fed horizontally or, preferably as shown, in a verticallydownward direction at a predetermined rate between the guide rolls 9, 9.Immediately above one of the guide rolls 9 is the feed pipe 10 supplyingliquid waterproofing material. The liq- .water-proofing material.

uid waterproofing material 11 flows into the space between the guideroll 9 and the felt 1 and thereby functions to fill the depressions 3with a predetermined quantity of liquid In its further travel, the felt1, the depressions 3 of which are filled withmaterial 11, may passbetween the smoothing rolls 12 which serve to remove any surplus ofwaterproofing material adhering to the strip of felt. After thedepressions have been thus filled with liquid waterproofing material,the strip of felt is preferably formed into a roll, the heat of theliquid waterproofing material and the contact of the successiveconvolutions of the roll causing the saturation or absorption to becomesubstantially complete, although if the sheet of felt is very hard orsomewhat non-absorbent, or if the saturant is very viscous, a smallamount of the saturant may not be absorbed and may remain on the surfaceof the sheet. After the saturation process is complete, the saturatedfelt may be used inany manner desired, as for sheathing or for otherpurposes, as for making the so-called rubber roofings of commerce.

Referring to the modification illustrated in Figs. 3 and 5, there isshown a strip 4 of felt provided on one side with the depressions 6defined by the elevated portions 5, the depressions 6 being staggeredwith respect to each other, while the other side of the strip of felthas the depressions 8 defined by the elevated portions 7, thedepressions 6 being staggered, not only with respect to 100 each other,but also with respect to the depressions 8. The strip4 is passed in avertically downward direction between the guide rolls 13 immediatelyabove which are the feed pipes 14 for supplying liquid water- 105proofing material 15 to both sides of the dry felt. The material 15collects between the guide rolls 13 and the felt 4 and fills thedepressions 6 and 8 in the material 15. The material in its furthertravel may pass be- 110 tween the smoothing rolls 16 which serve toremove any surplus of liquid waterproofing material adhering to thefelt. .After the felt has had the depressions thereof filled with thepredetermined quantity of liquid 115 waterproofing material, the'sameispreferably formed into a roll and the saturation process is completed inthe roll as a result of the heat stored in the liquid waterproofingmaterial and as a result of the contact tion of the saturating materialover and above what would be available if the sheet were smooth andunindented.

The dry felt of my invention, especially when made by the processdescribed, finds its principal application in my saturating process.Thesaturated felt, being provided with depressions or indentations ofsubstantially predetermined cubical content may be used generally as aconstruction material. The saturated felt finds particularapplicability, however, in the manufacture of the so-called rubberroofings of commerce, since portions of thecoating material will becomelodged or locked in the depressions, with the desirable result that thecoating will have less tendency to peel away from the saturated felt.This product and the process for making the same are claimed in myco-pending application entitled Coated construction materials andmethods of making the same, Serial No. 195,656, filed October 9, 1917. 1

What I claim is:

1. The method of saturating dry felt with liquid. Waterproofing materialwhich comprises providing at least one face of the felt with-a pluralityof depressions, filling the said depressions with the liquidwaterproofing materiah and causing said waterproofing material to besubstantially entirely absorbed by said felt.

2. The method of saturating dry felt with liquid waterproofing materialwhich comprises providing at least one face of the felt with a pluralityof depressions of predetermined cubical content, filling the saiddepressions with the liquid waterproofing material, and causing saidwaterproofingmaterial to be substantially entirely absorbed by saidfelt.

' 3. The method of saturating dry felt with liquid waterproofingmaterial which comprises providing at least one face of the felt with aplurality of staggered depressions of predetermined cubical content,filling the said staggered depressions withliquid waterproofingmaterial, and causing said waterproofing material to be substantiallyabsorbed by saidfelt.

4. The method of saturating dry felt I with liquid waterproofingmaterial which comprises providing both faces of the felt with aplurality of depressions of predetermined cubical content, filling thesaid depressions with liquid waterproofing mateeach other and to thedepressions on the other side, filling the said depressions with theliquid waterproofing material, and cans ing said waterproofing materialto be substantially absorbed by said felt.

6. The method of saturating dry felt with liquid waterproofing materialwhich comprises providing at least one face of the felt with a pluralityof depress-ions of predetermined cubical content, filling the saiddepressions with the hot liquid waterproofing material, and arrangingthe felt in a roll to permit the saturation to become complete and thesaturating material to be substantially absorbed by the felt.

7. The method of saturating dry felt with liquid waterproofing materialwhich comprises providing both faces of the felt with a plurality ofdepressions of predetermined cubical content, filling the saiddepressions With hot liquid Waterproofing material, and arranging thefelt in a roll to permit the saturation to become complete and thesaturating material to be substantially absorbed by the felt.

8. A construction material comprising a sheet of felt provided on atleast one side thereof with a plurality of depressions of predeterminedcubical content'which depressions leave the other side of the sheetsubstantially unaffected, said sheet being impregnated withwaterproofingmaterial.

9. A construction material comprising a sheet of felt impregnated with apredetermined amount of waterproofing material, and provided on at leastone side thereof with a plurality of depressions of predeter minedcubical content, which depressions leave the other side of the sheetsubstantially unaffected, said sheet being impregnated withwaterproofing material.

predetermined cubical content which depressions on one side leave theother side of the sheet substantially unaffected.

11. A construction material comprising a sheet of felt impregnated witha predetermined amount of waterproofing material, and provided on atleast one side thereof with a plurality of staggered depressions ofpredetermined cubical content which depressions on one side leave theother side of the sheet substantially unaffected.

12. A construction material comprising a sheet of felt impregnated withwaterproofing material, and provided on each side thereof with aplurality of staggered depressions of predetermined cubical contentwhich depressions on one side leave the other side of the sheetsubstantially unaffected.

In testimony whereof I afiix m signature. RAY P. ERRY.

